Blister package with closable cavities and uses thereof

ABSTRACT

A package for a product, the package comprising a body formed by layers of packaging material and at least one cavity formed by an outward projection of at least one of said layers, characterized in that one of said layers, in a region of said at least one cavity, is provided with a line of weakness or a cut in the material of said layer extending partially around an entrance to said cavity and defining a releasable hinged flap forming an openable and closable lid for said cavity.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is related to commonly owned co-pendingprovisional patent applications Serial Nos. 60/443,677 filed Jan. 29,2003 and 60/444,492 filed Feb. 3, 2003, and claims the benefit of theseearlier filing dates.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] This invention relates to blister packages having pre-formedcavities for holding products for display, sale, distribution and use.More particularly, the invention relates to blister packages havingpre-formed cavities preferably intended for holding dosages orselections of materials that have to be used at regular time intervals,in different quantities, or over an extended time period, or the like.The invention also relates to the use of such packages for thedispensing and use of materials, particularly medicaments.

[0004] 2. Background Art

[0005] Many products these days are displayed and sold in blisterpackages. Blister packages are containers that generally consist of athin-flat body having at least one cavity projecting from at least oneside of the body. The cavity is used for holding the product and thethin-flat body may be used as a support and/or as a medium fordisplaying advertising, decoration or product information. Quite often,the projecting cavity is made of a transparent plastic material so thatthe contents can be observed before the package is opened.

[0006] A special form of blister package is often used for materialsthat are required in dosage or metered form, such as for examplemedicines. In this case, more than one projecting cavity is provided ineach package so that the product can be divided into two or more dosesand the contents of each cavity can be removed and used separately fromthe contents of the other cavities. Perhaps the most well-known packageof this kind is the one developed for contraceptive pills many years agowhere a separate cavity is provided for each pill so that individualpills can be removed and consumed at appropriately-spaced timeintervals, e.g. on a daily basis. In this way, each dosage can be keptfresh, clean and uncontaminated until required for use, and the packageacts as a visual confirmation that a dose has been used on time.However, it has been usual in this kind of package to provide anindividual dosage form, e.g. a single pill or tablet, in each cavity.

[0007] In the conventional form of blister packages of this kind, the“blister” is made up of two parts, such as a flat rupturable foil layersealing the open end of a cavity formed in an adjacent layer. Thecontents of each cavity can then be removed individually, if the productis sufficiently rigid, by pressing down on the projecting cavity so thatthe contents, e.g. a pill, bursts through the foil closure.

[0008] One problem with packages of this kind is that the cavities arenot re-usable or re-sealable, once the contents have been removed andthe entire package is useless once the final dosage has been removed.Such packages are not convenient for holding several small groups ofproducts, e.g. tablets, that are not all consumed at the same time.Moreover, a package that is suitable for all potential users must bedesigned and modifications for different individuals are impossible.

SUMMARY OF THE INVENTION

[0009] An object of the preset invention is to provide packaging of theblister type that is more effective to use.

[0010] Another object of the invention, at least in preferred forms, isto provide a blister type package that can be used to customize aproduct for particular individuals or situations.

[0011] According to one preferred aspect of the present invention thereis provided a package for a product, the package comprising a bodyformed by layers of packaging material and at least one cavity formed byan outward projection of at least one of the layers, wherein one of thelayers, in a region of the at least one cavity, is provided with a lineof weakness or a cut in the material of the layer extending partiallyaround an entrance to the cavity and forming a releasable hinged flapforming an openable and closable lid for the cavity.

[0012] Preferably, the body is generally flat and made of two layer oftransparent material. By the term “generally flat” we mean that thelayers extend from the cavities in an approximate plane or shallow arc.Most preferably, the package has two or more cavities, and ideally 2 to7 or more.

[0013] In this way, a product held in the cavity, may be removed simplyby releasing the lid formed in the material of the other layer withoutcompletely disassembling the entire blister package or destroyingindividual blisters formed by the cavities.

[0014] Preferably, there are two or more cavities per package, eachprovided with a releasable lid of the type described above.

[0015] The or each lid preferably has a projection of suitable shape andsize to extend partially into the cavity formed from the other layer ofmaterial. In this way, the lid can be friction- or compression-fittedinto the opening of the cavity, so that the lid may be held securelywhen closed.

[0016] Additionally, the lid has an area forming a graspable tab so thatthe lid may be easily be grasped by the user and pulled away from theremainder of the package to open the cavity. Furthermore, the oppositelayer of material beneath the graspable tab may be provided with atleast one projection extending from the layer on the side facing thegraspable area. This causes the graspable area to stand proud of thelayer of material from which it is formed so that it is always readilyavailable to be grasped by the user.

[0017] The lid is preferably square or rectangular in shape and the lineof weakness or cut is formed along three sides, leaving the fourth sideto form a hinge about which the lid may pivot when released from thecavity.

[0018] The generally flat body may be used to support or contain printedmaterial indicating the contents of each cavity or the time or date ofwhich the contents of each cavity should be removed and consumed orused. The generally flat body may, of course, be used to support orcontain other printed material of an advertising, informative, ordecorative nature.

[0019] The blister package is most preferably made from a single pieceof heat-deformable, preferably transparent, plastic material in whichthe cavity or cavities and lines of weakness or cut may be made. Afterthis has taken place the material may be folded back on itself along aline and secured around the edges, e.g. by providing the edges withshapes that fit together by means of a friction fit.

[0020] An additional layer of material, e.g. made of paperboard orcardboard or the like, may be sandwiched between the two layers ofplastic material (with openings provided appropriately for the one ormore cavities) and provided with the intended decorative, informative oradvertising material or information.

[0021] The package of the invention is not only easy to use because theindividual lids can be removed from the cavities without disassemblingthe entire package, but the cavities can be re-closed, for example wheneach cavity is used to hold several dosages of material (e.g. severalpills or tablets) which are not intended to be used or consumed all atthe same time. For example, a package containing four re-closeablecavities of the above kind could be used to hold a product that has tobe consumed over four weeks at different dosages for each week. A firstcavity could then hold seven tablets of the material at one dosage leveland the other cavities could each hold seven tablets of the product atdifferent dosage levels. The user would then remove individual tabletson each day starting with the dosage intended for the first week andthen progressing to the cavity with the tablets intended for the secondweek.

[0022] The invention is particularly suitable for packaging fourstrengths of a product (e.g. a pharmaceutical provided in discretedosage form, e.g. tablets, pills, capsules, gelcaps and the like) in thesame package, or four weeks of dosage. In such cases, it was previouslynecessary to package the material in four separate bottles orcontainers. This facilitates those cases where a patient may have totake a regime of treatment requiring different dosages at differenttimes.

[0023] According to another aspect of the invention, there is provided amethod of distributing a product available in the form of a plurality ofdiscrete units, which method comprises dividing the units into aplurality of groups according to requirements of a specific user,introducing a different one of the plurality of groups into a differentcavity of package of the above type, closing each cavity with theassociated lid, providing the package with instructions regarding theremoval of the discrete units from the cavities, and distributing thepackage to the user of the product. The package of the invention canthus be used for customizing the product to a specific user or group ofusers, distribution to that user or group and then dispensing of theproduct while being used by the user or member of the group. The methodis particularly suitable for distribution of medicaments that must betaken in regular doses over time, especially where the product iscustomized to a user by a physician, packaged by a pharmacist accordingto a prescription from the pharmacist and used by a patient.

[0024] Thus, the product may be, for example, a medicament in the formof tablets, pills, capsules, or similar discrete units. Many medicamentsof this kind are prescribed by physicians in different ways fordifferent patients. For example, a patient may require a differentdosage at different times, or different combinations of medicaments atdifferent times. The package of the invention can be used to dispensemedicaments of this kind already divided into different dosage formsappropriate for use at the different times.

[0025] For example, the drug nefadozone HCl (referred to as Nefazodoneor Serazone) is often prescribed for depression. The drug is availablein the form of tablets of different dosages (e.g. 50 mg, 100 mg, 200 mg,etc.). Individual patients often require specific treatment regimes. Forexample, one patient may require one 50 mg tablet every day for a week,then one 100 mg tablet every day for a further week, and so on. Anotherpatient may require a 100 mg tablet once a day for four weeks, etc. Insuch circumstances, a physician would normally provide severalcontainers, each having tablets of the same dosage strength (all 50 mg,all 100 mg, etc.), and provide the patient with instructions regardingwhich strengths to use over time. However, this is costly andinefficient and prone to error if patients misunderstand theinstructions or choose a wrong container by mistake.

[0026] In such circumstances, it is possible to provide a blisterpackage according to the present invention with, say, four cavities,each cavity being intended to hold a supply of tablets for one week,thus making the package suitable for a four week supply. The cavitiesmay be numbered Week 1, Week 2, Week 3, Week 4, respectively. Accordingto the needs of a particular patient, a physician, or more likely apharmacist, would fill each cavity with tablets of an appropriatedosage. For example, the first cavity might be filled with tablets of 50mg strength, the second at 100 mg, the third at 100 mg and the fourth at200 mg. The patient would then merely consume the tablets from theappropriate for the week of treatment. The tablets may be removed byraising the lid of the selected cavity, removing one of the tablets, andthen closing the lid to keep the remaining tablets secure and sanitary.For a different patient, the cavities might be filled in a different way(e.g. all four containing tables of 50 mg strength).

[0027] Not only may the package of the invention be customized in thisway, but it may also be customized for different drugs or otherproducts. For example, a printed card or sheet may be positioned betweenthe layers of the generally flat body. By providing sheets printed withidentifying information for a number of different products, a packagecan be made ready for any one of those products by separating the layersof the generally flat body, inserting a card or sheet appropriate forthe product of interest, and then closing the package so that the cardor sheet is secured between the layers. Since the layers are preferablytransparent, the information provided on the card or sheet can be viewedthrough the body portion of the package and information about theproduct may be viewed.

[0028] Accordingly, the package of the present invention is readilycustomizable and is perfectly suited for accommodating a new way ofdistributing products, particularly medicaments, that is customized forindividuals that have individual needs. The package not only acts as ameans of distributing a product, but also as a means of temporarilystoring and dispensing the product until all is consumed. The simplicityand low cost of the package means that it can be discarded after usewithout adding unduly to the overall cost of the product.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029]FIG. 1 is top-plan view of a package according to one embodimentof the present invention;

[0030]FIG. 2 is an underneath plan view of the embodiment of FIG. 1;

[0031]FIG. 3 is a perspective view from above of the embodiment of FIG.1 with the lid of one of the cavities in the raised position;

[0032]FIG. 4 is a vertical cross-section of the embodiment of FIG. 1taken on the line IV-IV of FIG. 1; and

[0033]FIG. 5 is a vertical cross-section of the embodiment of FIG. 1taken on the line V-V of FIG. 1;

DETAILED DESCRIPTION OF THE INVENTION

[0034] A preferred embodiment of the blister package of presentinvention is shown in FIGS. 1 through 5 of the accompanying drawings.

[0035] The drawings show a blister package 10 having a generally flatbody 11 formed by two layers 12 and 13 of relatively stiff but flexiblematerial, preferably heat- or impact-deformable, transparent plasticmaterial (for example polyethylene terephthalate or other relativelytransparent material). The package 10 has four domed cavities 14extending outwardly from one of the layers 13 of the material. Thesedomed cavities form “blisters” for containing and preferably displayingproduct material. The cavities should preferably be made large enough tohold more than one item, e.g. tablet or capsule, and preferably largeenough to hold several such items (e.g. seven items, suitable for dailydoses for a week).

[0036] On the side of the package 10 opposite the domed cavities 14, theother layer 12 has lids 15 covering the entrance 16 of each domed cavity14. The lids 15 are defined by cuts or pre-formed tearable lines ofweakness 17 in the layer 12, but these cuts or lines of weakness do notextend fully around each cavity, thus leaving uncut or unweakenedsections 18 that may act as a flexible hinge 19 for each associated lid15. An advantage of the use of lines of weakness is that the interior ofthe package may remain completely sealed and sterile, and tampering isimmediately apparent in that the lines of weakness will then be tornopen and transformed to cuts in the material.

[0037] Each lid 15 preferably has a generally planar peripheral portion20 aligned with (and forming part of) the layer 12 and a central portion21 that projects inwardly from the layer 12 and extends for a shortdistance into the entrance 16 of the domed cavity 14. The centralportion 21 is shaped and dimensioned to fit snuggly within the entrance16 of the associated domed cavity 14, thus forming a secure friction- orcompression-fit which holds the lid securely within the opening of thecavity when in the closed position.

[0038] Each lid 15 is provided with an extension forming a tab 22 thatcan be grasped between the fingers of the user of the package tofacilitate removal of a lid 15 from an associated domed cavity 14, thusenabling removal of the contents (not shown) from the cavity.

[0039] Once a lid 15 has been removed in this way, it is held on thepackage by means of the flexible hinge 19 and can be repositioned overthe entrance 16 of the domed cavity 14 and secured in place once againby means of the friction- or compression-fit.

[0040] The layer 13 of material from which the domed cavities are formedmay be provided with outward projections 25 (preferably of half-moon(hemispherical) shape) beneath the tabs 22 so that the graspable tabs 22must stand proud of the plane of the layer 12 (see FIG. 4), thusimproving their accessibility to the user.

[0041] The layer 12 of material is also provided with a short, elongatedoutward projection 26 in the regions of the hinges 19 intended toprovide a greater range of movement for the hinges to facilitate theaction of the hinges and to reduce the danger that the lids 15 may betorn accidentally from the blister package 10.

[0042] It will be seen that the lid 15 of each domed cavity 14 may beopened and closed independently of the others so that the contents ofone domed cavity 14, or of several domed cavities or even of all domedcavities, may be accessed at the same or at different times.

[0043] A layer 30 of thin cardboard, paper or other printable materialis provided between the outer layers 12 and 13 of the blister package10. This layer 30 of material may carry printing or indicia to be seenby the user through the transparent layers 12 and 13. For example, thelayer 30 may bear numbers 31 to differentiate the domed cavities 14 fromeach other and/or to indicate the time periods (e.g. weeks) over whichthe contents of each cavity may be concealed or used. The printing mayalternatively be “Week 1”, “Week 2”, “Week 3” or “Week 4”, or a similarindication.

[0044] The card may also contain the name of the product and adecorative logo as well as product information and indication of thesource of the product. When the package is to be used for a number ofdifferent products, a different layer 30 may be provided for eachproduct with suitable product information and the appropriate oneselected when a package is being assembled.

[0045] The edges 33 of the blister package 10 may be held together byproviding the edges of each layer 12 and 13 with nesting profiles 34 and34′ that mutually engage and hold the layers together by means of afriction- or compression fit. This allows the package to be secured,while allowing it to be disassembled, if necessary. Alternatively, theedges 33 may be permanently sealed, if desired. Nevertheless, anon-permanent attachment of the edges in the manner described ispreferred so that a package made up for one particular product (or apackage containing no layer 30) may be opened and the layer 30 replacedor inserted for the first time. This makes the package customizable fora particular product, or changeable from one product to another withoutdifficulty.

[0046] The layers 12 and 13 are preferably formed from a single sheet ofplastics material that is bent back on itself at fold 36, thus forming ahinge 37. This gives the package a “clam-shell” (book hinge) design orstructure.

[0047] During manufacturing, the domed cavities 14 are formed by heatmolding or stamping in a line on one side of the hinge 37 and the linesof weakness or cuts 17 for the lids 15 are formed by stamping on theother side with the cavities and the lids in proper alignment forcorrect positioning when the sheet is bent back on itself around thehinge 37. The half-moon projections 25 and elongated hinge 27 are alsoformed at the same time as the cavities 14 and/or cuts 17, as well asthe profiled edges 33. All of this can be done in a single operationstarting from a flat sheet of the plastics material. The layer 30 ofcard (preprinted with desired information or indicia) may be sandwichedwithin the blister package as the halves of the sheet forming the layers12 and 13 are folded against each other via hinge 37.

[0048] In use, the illustrated embodiment may be used to facilitate anovel method of packaging and distributing items, particularlymedicaments. For example, a physician may prescribe for a patient a fourweek course of medication produced in the form of tablets of differentstrengths. When filling the prescription, the pharmacist selects apackage 10 and inserts a layer 30 appropriate for the medicament(showing the name of the medicament, dosage information, labeling forthe cavities, decoration, patent and trademark information, etc.). Thelayers 12 and 13 are then brought together and secured at their edges.The pharmacist then fills each cavity with a dosage form appropriate forone week, using tablets having a strength suitable for the first week inthe first cavity, tablets having a strength suitable for the second weekin the second cavity, etc. The lids 15 are then closed to temporarilyseal the package and a label typical for a medicament container may beapplied to the outside or inside of one of the layers 12 and 13. Thepackage is then given to the patient, who will select tablets from thefirst cavity during the first week, the second cavity during the secondweek, etc. This facilitates distribution and proper use of the product.

[0049] Although a preferred embodiment of the invention has beendescribed in detail above, it will be apparent to persons skilled in theart that other embodiments and variations may be employed withoutdeparting from the scope of the invention.

What we claim is:
 1. A package for a product, the package comprising abody formed by layers of packaging material and at least one cavityformed by an outward projection of at least one of said layers, whereinone of said layers, in a region of said at least one cavity, is providedwith a line of weakness or a cut in the material of said layer extendingpartially around an entrance to said cavity and defining a releasablehinged flap forming an openable and closable lid for said cavity.
 2. Thepackage of claim 1, having two or more of said cavities, each providedwith said releasable hinged flap forming an openable and closable lid.3. The package of claim 1, having 2 to 7 of said cavities, each providedwith said releasable hinged flap forming an openable and closable lid.4. The package of claim 1, wherein the body is generally flat and madeof two overlying layers of material.
 5. The package of claim 4, whereinsaid layers are transparent.
 6. The package of claim 1, wherein saidhinged flap has a projecting part of shape and size to extend partiallyinto the cavity while enabling friction- or compression-fitting of thehinged flap into the cavity.
 7. The package of claim 1, wherein saidhinged flap has an area forming a graspable tab enabling said flap to begrasped by a user and pulled to open the cavity.
 8. The package of claim7, wherein said body is made of two overlying layers of material, one ofsaid layers lying beneath said graspable tab being provided with atleast one projection extending outwardly from the layer on the sidefacing the graspable tab thereby causing the graspable tab to standproud of the layer of material from which it is formed.
 9. The packageof claim 1, wherein the hinged flap is square or rectangular in shapeand the line of weakness or cut is formed along three sides of saidflap, leaving a fourth side to form a hinge about which the flap maypivot.
 10. The package of claim 1, wherein said body supports orcontains printed material.
 11. The package of claim 1, wherein said bodyis made from a single piece of heat-deformable plastics material inwhich said at least one cavity is formed and said lines of weakness aremade.
 12. The package of claim 11, wherein said single piece of materialis folded into two parts that overly eachother, and edges of saidrespective pieces are secured together.
 13. The package of claim 12,wherein said edges are secured by providing said edges with profilesthat nest together and engage with a friction fit.
 14. The package ofclaim 12, wherein said single piece of heat-deformable plastics materialis transparent and a printed sheet is sandwiched between said twopieces.
 15. The package of claim 14, wherein said printed sheet hasprinting adjacent to each cavity distinguishing each cavity from theothers.
 16. The package of claim 15, having four cavities, wherein saidprinting comprises the wording “Week 1” adjacent to a first cavity,“Week 2” adjacent to a second cavity, “Week 3” adjacent to a thirdcavity, and “Week 4” adjacent to a fourth cavity.
 17. A blister packagefor a product made up of a plurality of discrete units, the blisterpackage comprising a body formed by layers of packaging material and aplurality of blister cavities formed by outward projections of at leastone of said layers, wherein one of said layers, in a region of each saidcavity, is provided with a releasable hinged flap forming an openableand closable lid for each said cavity.
 18. A method of distributing aproduct available in the form of a plurality of discrete units, whichmethod comprises dividing the units into a plurality of groups accordingto requirements of a specific user of the product, introducing adifferent one of the plurality of groups into a different cavity thepackage of claim 1 having a plurality of cavities, closing each cavitywith said associated lid, providing the package with instructionsregarding the removal of the discrete units from the cavities, anddistributing the package to the user of the product.
 19. The method ofclaim 18, wherein said discrete units are dosage forms of a medicamentthat must be taken in regular doses over time.
 20. The method of claim19, wherein said discrete units are dosage forms selected from the groupconsisting of tablets, pills, capsules, and gelcaps.